Composite felt and process op making the same



R. PrPERRY; COMPOSITE FELT AND PROCESS OF MAKING THE SAME.

APPLICATION FILED .IUNEB. 1922.

6 2 lw p e S M w S :1 DU 3 ATTORN EY INVENTOR Reissued Sept. 26, 1922.

UNITED STA'MILES PATENT OFFICE.

RAY P. PERRY, OF UPPER MON'ICLAIR, NEW JERSEY, ASSIQ NOR TO'THE BARRETT COMPANY, A CORPORATION OF NEW JERSEY.

, COMPOSITEFELT AND PROCESS OF MAKING THE SAME.

Original No. 1,288,158, dated December 17, 1918, Serial No. 162,121, filed April 14, 1917.

reissue filed June 3, 1922. Serial No. 565,736.

To all whom it may concern;

Be it known that I, RAY P. PERRY, a citizen of the United States, residing at U per Montclair, in the county of Essex and tate of New Jersey, have invented certain new and useful Improvements in Composite Felts and Processes of Making the Same, of which the following is a specification.

This invention relates to dry felts or papers used for making roofing or construc.

tion materials or for use as sheathing or building papers and for other uses. The felt which is the object of my invention contains, while still in the dry state, a predetermined proportion of bituminous ma terial in comminuted form, as in filamentary form, for example.

' Such bituminous dry felts or papers have been described in the specification of the Letters Patent No.-1,305,404,

- granted to me June 3, 1919.

In the manufacture of dry felts containing a certain proportion of bituminous material in comminuted form, difficulty is sometimes experienced in manufacturing such felts due to the fact that in the drying operation, which is a necessary step in the manufacture of such felts, if the felt contains a high percentage of bituminous material, such as pitch or asphalt, the same oft-en sticks or adheres somewhat to the hot drying rolls with the result that such rolls collect some bituminous material and may,

as a result of such collected material, in-

jure or damage the surface of the roofing material. Such adhesion also reduces the heat transmission and hence the efficiency of such rolls for drying purposes. This diflic ulty is experienced especially when the dry felt, containing the comminuted bituminous material, has a percentage of such material, though some difiiculty may be experienced with felts containing a lower per centage of such bituminous material especially where the drying rolls are very hot.

By my method such difiiculties are'en; tirely avoided. Moreover, it is possible by my method to prepare a dry felt or paper containing a very large percentage of bitu- A pplication for These, and other desirable objects, are

obtained in the following manner:

Instead of making the felt in a single 5 uniform sheet or layer consisting of a predetermined mixture of bituminous filaments or bituminous material in any other commlnuted form added to the usual pul mixture consisting of rags and paper, make.

the dry bituminous felt in the form of a composite sheet. as follows: I

Instead of having a single forming cylinder and couche roll; I have a plurality of such cylinders and corresponding couche rolls, generally three in number. The composite sheet which is the object of my invention is made in three layers generally. The intermediate layer is formed with a very high percentage of bituminous comminuted material in the same. The surface layers, however, either contain no bituminous material at all orcontain such material in a percentage low enough to prevent any undesired adhesion of such material or layers to the drying rolls when the composite felt is being dried; In operation the three layers comprising an inner layer rich in bituminous material and two outer layers either containing no such material at all or containing 'only a slight quantity of such material, are formed and more or less matted or felted together in the wet state and then passed to the heated drying rolls together where, under the action 'of the drylng rolls, the layers are further cemented or fused together into a sin- .ing agent. For a similar reason it is pomible by my process to make a felt of any desired thickness, since the usual difficulty experienced in the splitting apart of felts of My mode of procedure is great thickness when formed in separate sheetsor layers in a several-cylinder paper machine, is avoided due to the cementing action of the intermediate layer or layers rich in bituminous material. No matter how thick the composite sheet may be, the intermediate layer prevents any separation or splitting apart of the component sheets after the formation of the felt since said layer acts as a cementing agent.

My, invention comprises the product as well as the proces. Referring to the drawing where I have illustrated my invention, Figure 1 shows diametrically a device wherein-my process may be practised and my product may be produced.

Fig. ,2 shows in magnified cross-section the composite felt which is the result of my invention.

Fig. 3 shows in magnified cross-section a modified composite sheet made up of two layers only.

The composite sheet which is the object of my invention is made as follows:

1 is a layer containing a large percentage of comminuted bituminous material, such as soft or hard coal tar pitch, asphalt or other ,solid bituminous material in the form of regular or irregular fragments, powder, shot, filaments, orfragments of the same, etc., 'as described in Letters Patent No. 1,305,404, above referred to. Hereafter, in the specification and claims I shall refer to these classes of materials'underthe common desi ation of bituminous materials.

'T e stockfrom which this layer is made,

.in addition to comminuted bituminous ma-v terial (generally amounting, if desired, to more than 10% and less'than 90% of the total Stock) consists of a mixture of rags and paper in the form of a watery pulp, the

'whole beingintimately mixed together, all

as. described in ,my 'copending application above referred to. As a result of the addition of comminuted bituminous material, especially when such material is in filamentary form, I may use a larger proportion of paper or-hard stock, and a'smaller proportion of rags orsoft' stock than has hitherto been deemed feasible, and still leave the roofing material open and porous enough for tent, to spread and keep such material open.

subsequent saturation. This result is. due to the fact that the particles of bituminous material, especially when the same are of filamentary form, arescattered through the roofing material and serve, to a certain exand porous. I may use, for example,-a mixture containing 50% of bituminous material V in comminuted form, 25% rags and 25% paper, in the form of a watery pulp, with considerable success.

This mixture S is placed in the inner cyl-- inder vat 4. of a several-cylinder paper-makmaterial containing either no bituminous material in comminuted form, such as filaments of pitch or fragments thereof, or

else containing such material in proportions which will not cause the la ers 2, 3 formed from the mixtures S and vats 4 to adhere to the drying rolls during the drying operation. Any number or arrangement .of the cylinder vats 4 4,, 4,, may be employed, three being shown as arranged in the drawing merely by way of illustration.

Within the cylinder vats 4 4,, 4:, ,are the respective perforated cylinders 6 6 6 (:0- operating with the wet felt endless belt 8 and the couche rolls 7 7,, 7 to form the component layers 2, 1 and 3, respectively, of the composite sheet 5. The layer 2 poor in comminuted bituminous materialor containing no such material at all is formed fromthe material S in the vat 4 being carried on the under side of the "wetfelt 8 until it picks up the layer 1 rich in bituminous material, the layer 1 being made'from the ma-' terial S in the vat 4,, The wet felt 8, now carrying a composite sheet'ma'de up of the two layers 2, 1, the layer 2' being in contact withthe' felt and the layer 1 being in contact with the layer 2, picks up the further layer 3, poor in comminuted bituminousma: terial or containing no such material at all, so that the'composite sheet 5, after it leaves the last couche roll, consists ofthree layers, 2', 1, 3, the intermediatelayer 1 being rich in comminuted bituminous material and the outer layers 2, 3 being poor in such ma terial, or containing no such material at all.

ling condition being that while the inter- 1 mediate layer 1 may be as rich as desired in' comminuted bituminous material, the-outer layers 2, 3, should contain a low enough percentage of comminuted bituminous material to substantially prevent the composite felt] from sticking to the drying rolls during the drying operation. Where the drying is caused to proceed from a drying roll or rolls or other drying means contacting with but one :side of 'the composite felt,"a com- 1 posite felt 5 may be made consisting of but, one layer 2 of'material poor in comminuted material and another layer 1 rich in s ch material, the composite sheet 5' passing 0 er the drying roll or other heating device in 1' 3 in the cylinder I contact with that side of the composite sheet which is covered by the layer 2 poor 1n comminuted bituminous material.

' The action of the drying roll or rolls helps to cause the component layers to unite, and the bituminous material present in the layer rich in bituminous material furthers the uniting action by being somewhat softened or fused by the heat from the drying rolls, thereby cementing the composite sheet into a strong unitary structure. The composite sheet whether consisting of two, three or more layers, may be saturated with Water proofing material or coated with such or analogous material, or both, in the manner usual in the manufacture of so-called rubber roofings. Usually the waterproofing and coating material consists of bituminous materials such as pitchor asphalt. While the thickness of the composite layers may be varied at will,'and While the relative proportions in the thickness of the complete sheet or each of the component layers may be varied as desired, it is customary to make the layer rich in bituminous material comparatively thick and the layer or layers poor in comminuted bituminous material comparatively thin, thereby providing the composite sheet with a maximum content of bituminous material.

The component sheet, however, need not be saturated. but may be used in the dry state. For example,.I may make dry sheathing or dry paper by my process. In such case the watery pulp stock may for all 'purposes be made largely or entirely of old papers or similar material and, if desired, the outer layers may be colored red, blue, etc., either by mixing color with the stock or by later appl ing the same after the sheets are formed. he interior layer or layers may be rich in bituminous material in solid form and serve to'make the sheathing paper more damp resistant, and have other advantages. The composite sheet may obviously be made in various combinations and used for a variety of purposes.

Throughout the specification and claims Wherever I refer to material as being poor in bituminous matter, or as containing a smaller or a comparatively small proportion of such matter, I mean to include by such terms those instances where the material contains no bituminous matter at all.

What I claim is i 1 A composite strip of paper comprising a layer of material containing a predetermined quantity of fusible bituminous matter in comminuted form, and at least one other layer of material united to the first layer and containing a smaller proportion of bituminous material than said first-mentioned layer, substantially as described.

2. A composite strip of paper comprising a layer of material containing a predeterform than said first-mentioned layer, substantially as described.

3. A composite strip of paper comprising 'a' layer of material containing a predetermined quantity of comminuted bituminous matter and two other layers of material united to the first layer, one on each side of said first-mentioned layer and each containinga smaller proportion of bituminous matter in comminuted form than said first-mentioned layer, substantially as described.

4. A composite strip of paper comprising a layer of fibrous material containing comminuted asphalt, and at least one other layer of fibrousmaterial united to the first layer and containing a smaller proportion of asphalt than said first-mentioned layer, substantially as described.

5. A composite strip of paper comprising a layer of fibrous material containing comminuted asphalt, and two other layers of fibrous material united to the first layer, one

on each side of said first-mentioned layer I and each containing a smaller proportion of asphalt than said first-mentioned layer, substantially as described.

6. A composite strip of paper comprising a layer of material containing between 30% and 90% of fusible comminuted bituminous matter, and at least one other layer of material united to the first layer and containing less than 40% of bituminous matter,

substantially as described.

7. A composite strip of paper comprising a layer of material containing more than 30% of fusible comminuted bituminous matter and two other layers of material united to the first layer, one on each side of said first layer, and containing each less than 40% of bituminous matter, substantially as described.

8. The process of making paper which "comprises the steps of forming a layer of material containing a comparatively large proportion of fusible comminuted bitumi-. 'nous matter, forming a second layer of material containing a comparatively small quantity of bituminous matter, and causing said layers to become united in an integral sheet, substantially as described.

9. The process of making paper which comprises the steps of forming a layer of material containing a comparatively small quantity of bituminous matter, forminga second layer of material, containing a comparativel large proportion of fusible comminuted ituminous matter, forming a third layer of material containing a comparatively small proportion of. bituminous matter, the second-mentioned layer being located between the other two layers, and causing said layers to become united into a single composite sheet, substantially as described.

10. The process of .making paper which comprises the steps of forming a layer of material containing a comparatively, large proportion of comminuted bituminous matter, forming a second layer of material containing a comparatively small quantity of comminuted bituminous matter, and causing said layers to become united in an integral sheet, substantially as described.

11. The process of making paper which comprises the steps of forming a layer of material containing a comparatively small quantity of comminuted bituminous matter, forming a second layer of material containing a comparatively large proportion of comminuted bituminous matter, forming a third layer of material containing a comparatively small proportion of comminuted bituminous matter, the second-mentioned layer being located between the other two layers, and causing said layers to become united into a single composite sheet, substantially as described. I

12. The process of making paper which comprises the steps of forming a layer of material containing a comparatively small proportion of comminuted bituminous ,matter, forming a second layer of material containing a comparatively large proportion of comminuted bituminous matter, and heating said layers to cause'the same to become united into a unitary sheet, the union being assisted due to the cemented action of the comminuted bituminous material present in the sheet, substantially as described.

13. The process of making paper, which consists in forming a sheet containing comminuted asphalt, applying thereto one or. .more layers of paper containing a smaller! 4 proportion of asphalt, and drying the same.

14. The procew of making paper, which comprises the steps of forming on a papermaking machine a' layer of fibrous material .containing more than 30% of comminuted asphalt, forming a second layer of fibrous material containing a smaller proportion of asphalt, and causing said layers to become united, substantially as described.

15. The process of making paper which comprises forming in a paper-making machine a layer of fibrous material, rich in comminuted bituminous material, forming at least one other layer of fibrous material on a paper machine, matting or felting said layers together in a wet state, and then passing over heated drying rolls to further cementthe layers togetherinto a single composite sheet. 7 g

- 16. The process of making paper. which comprises, forming three layers of fibrous material in a paper-making machine, the,

comprises the steps of formingon a paper-,

making machine a. layer of fibrous material containing a comparatively large proportion of comminuted material, forming a second layer on a paper-making machine of fibrous material containi a comparatively small quantity of comminuted bituminous material, and causing said layers to become united in an integral sheet by matting or. felting them together in the wet state, and then further cementing them together by passing over heated drying rolls.

18. The rocem of making paper which comprises inning in a paper-making machine a layer of fibrous material, rich in comminuted asphalt, forming at least one other layer of fibrous material on a paper machine, matting or felting said layers together in a wet state, and then passing over heated drying rolls to further cement the layers together into a single composite sheet.

comprises forming three layers of fibrous material in a paper-making machine, the inner layer being rich in comminuted asphalt, matting or felting the three layers together in the wet state, and then further cementing the layers into a single composite sheet by passing over heated drying rolls.

20. The process of making paper which comprises the steps of forming on a papermaking machine a layer of fibrous material containing a comparatively large proportion of comminuted asphalt, forming a second layer on a paper-making machine of fibrous material containing a comparatively small quantity of comminuted asphalt, and causing said layer to become united in an integral sheet by matting or felting them together in the wet state, and then further cementing thialm together by passing over heated drying r0 s.

In testimony whereof I aflix my si RAY P. PE RY.

ature.

19. The process of making paper which 

